Challenger/Cuda without Factory Air Evaporator Kit EDZ

Transcription

1 an ISO 9001:2015 Registered Company Challenger/Cuda without Factory Air Evaporator Kit EDZ Goll St. San Antonio, TX Phone: Sales: Tech Support: EDZ REV F 08/21/18, PG 1 OF 24

2 Table of Contents 1. Cover 2. Table of Contents 3. Packing List/Parts Disclaimer 4. Information Page 5. Wiring Notice 6. Engine Compartment Figure 1 7. Condenser, Compressor Bracket & Passenger Compartment Figure 2 8. Passenger Compartment (Cont.), Defrost Duct and Fresh Air Cap Installation Figures 3, 4 & 5 9. Evaporator Installation Figure Evaporator Installation (Cont.) Figures 7, 7a & 7b 11. Firewall Cover Installation Figure Drain Hose Installation Figure A/C & Heater Hose Installation 14. A/C Hose Routing Figure Heater Control Valve Installation Figure Control Panel Wiring & Duct Hose Routing Figure Under Dash Louver Bezel Installation Figures 13 & Evaporator Hardline & Bracket Installation Figure Wiring Diagram 20. Gen IV Wiring Connection Instructions 21. Operation of Controls 22. Troubleshooting Information 23. Troubleshooting Information (Cont.) 24. Evaporator Kit Packing List EDZ REV F 08/21/18, PG 2 OF 24 2

3 No. Qty. Part No. Description Packing List Evaporator Kit ( EDZ) VUE PMN Gen IV 4-Vent Evaporator Sub Case Accessory Kit Challenger/Cuda without A/C ** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items. 1 Gen IV 4-Vent Evap. Sub Case VUE 2 HOT COLD OFF HI DASH FLR DEF A/C HOT COLD Accessory Kit PMN NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities EDZ REV F 08/21/18, PG 3 OF 24

4 Important Notice Please Read For Maximum System Performance, Vintage Air Recommends the Following: NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components. Refrigerant Capacities: Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance. Other Systems: Consult manufacturer s guidelines. Lubricant Capacities: New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge). All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added). Safety Switches Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant. Service Info: Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen. Evacuate the System for Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85 F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications. Bolts Passing Through Cowl and/or Firewall: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation. Heater Hose (Not Included With This Kit): Heater hose may be purchased from Vintage Air (Part# VUD) or your local parts retailer. Routing and required length will vary based on installer preference EDZ REV F 08/21/18, PG 4 OF 24 4

5 Important Wiring Notice Please Read Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed. There Should Be a Capacitor Found At Each of the Following Locations: 1. On the positive terminal of the ignition coil. 2. If there is a generator, on the armature terminal of the generator. 3. If there is a generator, on the battery terminal of the voltage regulator. Most alternators have a capacitor installed internally to eliminate what is called whining as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator. It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis. If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems, charging systems, and from switching some of the vehicle s other systems on and off. Modern computer-operated equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected resets, strange behavior, and/or permanent damage. Vintage Air strives to harden our products against these types of electrical noise, but there is a point where a vehicle s electrical system can be degraded so much that nothing can help. Radio interference capacitors should be available at most auto and truck parts suppliers. They typically are cylindrical in shape, a little over an inch long, a little over a half inch in diameter, and they have a single lead coming from one end of the cylinder with a terminal on the end of the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The specific value of the capacitance is not too significant in comparison to ignition capacitors that are matched with the coil to reduce pitting of the points. Care must be taken, when installing the compressor lead, not to short it to ground. The compressor lead must not be connected to a condenser fan or to any other auxiliary device. Shorting to ground or connecting to a condenser fan or any other auxiliary device may damage wiring, the compressor relay, and/or cause a malfunction. When installing ground leads on Gen IV systems, the blower control ground and ECU ground must be connected directly to the negative battery post. 5 For proper system operation, the heater control valve must be connected to the ECU EDZ REV F 08/21/18, PG 5 OF 24

6 Engine Compartment NOTE: Before starting the air conditioner installation, check all components (radio, lights, wipers, etc.) for proper operation and study the instructions, illustrations and diagrams. 1. Disconnect battery. 2. Drain radiator. 3. Remove hood latch assembly. 4. Remove OEM heater hoses from water pump and intake. 5. Remove OEM heater hoses from heater lines coming through firewall. 6. Remove OEM blower assembly. Blower Assembly Heater Hose (From Intake) Heater Hose (From Water Pump) Figure 1 Hood Latch Assembly EDZ REV F 08/21/18, PG 6 OF 24 6

7 DEF Condenser Assembly & Installation 1. Refer to separate instructions included with the condenser kit to install the condenser Compressor & Brackets 1. Refer to separate instructions included with the bracket kit to install the compressor bracket. Passenger Compartment To ease installation, loosen the top (4) dash mounting bolts located in the defrost ducts along the bottom side of the windshield, as well as the (2) side dash mounting bolts. Pull dash away from windshield to remove (4) OEM defrost duct mounting screws (See Figure 3, below). Remove OEM defrost duct assembly (See Figure 2, below). Remove the passenger side fresh air lever and cable (discard). Disconnect the driver side fresh air lever at dash and relocate approximately as shown under dash using existing holes. (4) OEM Mounting Screws OEM Defrost Duct Assembly LOW FAN HIGH WARM Figure 2 COOL TEMP MAX A/C COOL A/C HEAT New Location For Driver Side Fresh Air Lever & Cable (Use Existing OEM Holes Under Dash) Driver Side Fresh Air Lever (Disconnect & Relocate) Pass. Side Fresh Air Lever & Cable (Remove And Discard) EDZ REV F 08/21/18, PG 7 OF 24

8 LOW DEF Passenger Compartment (Cont.) Remove the OEM heater assembly from under dash as shown in Figure 3, below. Remove the OEM control panel assembly from dash as shown in Figure 3, below. Refer to control panel conversion kit instructions for installation of controls. COOL TEMP MAX A/C FAN HIGH COOL A/C HEAT WARM Figure 3 1. OEM Control Panel Assembly OEM Heater Assembly Defrost Duct Installation Using the OEM mounting screw, install the new defrost ducts as shown in Figure 4, below. Defrost Duct OEM Screw OEM Screw Figure 4 Fresh Air Cap Installation 1. Using (2) #10 x 1/2 sheet metal screws install the fresh air cap as shown in Figure 5, below EDZ REV F 08/21/18, PG 8 OF 24 Figure 5 (2) VUB #10 x 1/2 Sheet Metal Screws PME Fresh Air Cap 8

9 Evaporator Installation Mark front evaporator mounting bracket hole locations on inner cowl (See Figure 7a, Page 10). Once holes are marked in the correct location, drill 1/8" holes in inner cowl for front evaporator bracket mounting location. Mark and drill (2) 9/32" holes for driver/passenger side evaporator rear mounting bracket in firewall (See Figure 7b, Page 10). On a workbench, install evaporator rear bracket and hardlines with properly lubricated O-rings (See Figure 10a, Page 14 and Figure 15, Page 18). Install front mounting bracket on evaporator using (2) 1/4-20 x 1/2" hex bolts and tighten as shown in Figure 6, below. Lift evaporator unit up under the dashboard (See Figure 7, Page 10). Secure loosely to the firewall from the engine compartment side using (2) 1/4-20 nuts and washers (See Figure 7, Page 10). Using (2) #14 x 3/4" sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 7, Page 10). Verify that evaporator unit is level and square to the dash. Then tighten all mounting bolts. NOTE: Tighten the bolt on firewall first. Then tighten the front mounting bracket screws. (2) 1/4-20 x 1/2 Hex Bolts Figure EDZ REV F 08/21/18, PG 9 OF 24

10 Mark & Drill 9/32 Holes Mark & Drill 1/8 Holes 4 4" 2 8 3/8" 8 1/4" Passenger Side Firewall 1 7/8" 7 Figure 7b Firewall Figure 7a View Through Dash (2) 1/4-20 Nuts w/ Washers Inner Cowl Figure 7 (2) #14 x 3/4 Sheet Metal Screws EDZ REV F 08/21/18, PG 10 OF 24 10

11 Firewall Cover Installation Apply 1/4 bead of silicone around the back side of the firewall cover as shown in Figure 8, below. Pass lines through firewall cover and secure with (3) 7/16" panel retainers (See Figure 8, below). Install (2) VUI rubber plugs in OEM heater holes as shown in Figure 8, below. OEM Heater Holes (2) VUI Rubber Plugs (3) MSR 7/16" Panel Retainers Back Side of Firewall Cover Figure 8 Silicone EDZ REV F 08/21/18, PG 11 OF 24

12 1. 2. Drain Hose Installation In line with the drain, lightly make a mark on the firewall. Measure one inch down and drill a 5/8 hole through the firewall (See Figure 9, below). Install drain hose to bottom of evaporator unit and route through firewall (See Figure 9, below). 1 Drain Hose Drain Figure EDZ REV F 08/21/18, PG 12 OF 24 12

13 A/C Hose Installation 1. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 10a, Page 14) and connect the 90 fitting to the #10 suction port on the compressor, and then route the straight fitting to the #10 evaporator hardline coming through the firewall (See Figure 10, Page 14). Tighten each fitting connection as shown in Figure 10a, Page 14. NOTE: The #10 A/C hose 90 fitting at the compressor must be installed below the #8 135 hose fitting. This needs to be done so the air filter box is not pushed out of position by the #10 A/C hose. In some cases the fuel filter may block the routing of the #10 hose, if so the fuel filter will have to be relocated to clear the routing of the #10 hose. Wrap the #10 fitting connections at the firewall with press tape (See Figure 10, Page 14). 2. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 10a, Page 14) and connect the 135 fitting to the #8 discharge port on the compressor, and then route the 45 fitting to the #8 condenser hardline on the fender well (See Figure 10, Page 14). Tighten each fitting connection as shown in Figure 10a, Page Locate the #6 evaporator/core hardline. Lubricate (2) #6 O-rings (See Figure 10a, Page 14) and connect the hardline to the #6 drier/core hardline on the fender well from the drier. Attach the other end of the hardline with lubricated O-ring to the #6 evaporator hardline coming through the firewall (See Figure 10, Page 14). Tighten each fitting connection as shown in Figure 10a, Page 14. Use a #2 Adel clamp to secure the #6 evaporator/core hardline to the inner fender well as shown in Figure 10, Page 14. Secure the Adel clamp to the inner fender using a #10 x 1/2 sheet metal screw. Modified A/C Hose 1. Refer to separate instructuons included with modified hose kit. Heater Hose & Heater Control Valve Installation 1. Route a piece of heater hose from the water pump to the heater line coming through the firewall as shown in Figure 10, Page 14, and Figure 11, Page 15. Secure using hose clamps. 2. Route a piece of heater hose from the intake to the heater line coming through the firewall as shown in Figure 10, Page 14, and Figure 11, Page 15. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 11, Page 15. Also note proper flow direction EDZ REV F 08/21/18, PG 13 OF 24

14 Figure 10a FIGURE 8 Figure 10 Press Tape #6 O-ring Press Tape #8 O-ring Expansion Valve Firewall Cover Hose Routing #10 O-ring O-ring Male Insert Female Nut #2 & #4 Adel Clamp #10 x 1/2" Sheet Metal Screw #10 A/C Suction Hose (Compressor/ Evaporator) #6 Evaporator/Core Hardline ( EFL) #2 & #10 Adel Clamp #10 x 1/2" Sheet Metal Screw Heater Control Valve #8 A/C Discharge Hose (Compressor/ Condenser Hardline) #8 Condenser Hardline ECU Module #10 O-ring Supplied Oil for O-rings #8 O-ring #8 O-ring Evaporator Sub Case #10 Suction Line (Insulated) O-ring, Slide Over Male Insert to Swaged Lip EDZ REV F 08/21/18, PG 14 OF 24 #2 & #4 Adel Clamp #10 x 1/2" Sheet Metal Screw NOTE: For a proper seal of fittings, install supplied O-rings as shown and lubricate with supplied oil. #6 Drier/Core Hardline Hold With This Wrench Twist With This Wrench Lubricate O-ring 14

15 Heater Control Valve Installation Press Tape ECU Module #10 Suction Line (Insulated) Expansion Valve O-ring #10 Suction Hose #6 Liquid Line Firewall Cover To Water Pump From Htr Cntrl Vlv Heater Hose Figure 11 NOTE: Flow direction follows molded arrow on valve. From Intake Duct Hose Routing, Control Panel Harness & Under Dash Panel Installation Install duct hoses as shown in Figure 12, Page 16. Plug the control panel harness into the ECU module on the sub case as shown (See Figure 12, Page 16). Route the control panel harness under the center dash assembly and connect the control harness to the PC board assembly on the back side of the control panel as shown in Figure 12, Page 16. Plug the wiring harness into the ECU module on the sub case as shown (Wire according to wiring diagram on Page 19). Reinstall control panel. Refer to control panel conversion kit instructions EDZ REV F 08/21/18, PG 15 OF 24

16 S B Y Control Panel & Duct Hose Routing Back Side of PC Board Assembly Control Panel Harness From ECU VUR Pass. Side Louver 2 ½ X 48 Pass. Side Def. Duct 2 X 16 Plug From Control Wirng Harness VUR Driver Side Def. Duct 2 X 18 Plug From Wiring Harness VUA Passenger Side Louver Driver Side Louver 2 ½ X 36" Center Louver Driver Side 2 ½ X 20 Center Louver Pass. Side 2 ½ X 26 Driver Side Louver Figure 12 Center Louver Passenger Side Center Louver Driver Side EDZ REV F 08/21/18, PG 16 OF 24 16

17 Under Dash Louver Bezel Installation Using (3) #8 x 1/2 pan head screws, install the under dash louver bezel, and align with OEM holes in the dash as shown in Figure 13, below. Install louvers as shown in Figure 14, below. Reinstall all previously removed items (Battery box & battery). Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water. It is the owner's responsibility to keep the freeze protection at the proper level for the climate in which the vehicle is operated. Failure to follow antifreeze recommendations will cause heater core to corrode prematurely and possibly burst in A/C mode and/or freezing weather, voiding your warranty. Double check all fittings, brackets and belts for tightness. Vintage Air recommends that all A/C systems be serviced by a certified automotive air conditioning technician. Evacuate the system for a minimum of 45 minutes prior to charging. Leak check prior to servicing. Charge the system to the capacities stated on the information page (Page 4) of this instruction manual VME Under Dash Louver Bezel Figure 13 (3) VUB #8 x 1/2 Pan Head Screws (3) LUA Louvers Figure EDZ REV F 08/21/18, PG 17 OF 24

18 NOTE: After installing #10 suction line, wrap all exposed metal (fittings & tube) with supplied press tape. Press Tape Figure 15 #10 Suction Line (09151-PCS) Evaporator Hardline Installation #10 O-ring (33859-VUF) #6 O-ring (33857-VUF) Heater Line (Evap to Water Pump) PCH Heater Line (Evap to Intake) PCH ECU Module Driver Side (Evap. Brkt) PCB Pass. Side (Evap. Brkt) PCB VUB 1/4-20 x 1/2" Coarse Bolt w/ VUB Flat Washer #6 Liquid Line (09150-PCL) Twist With This Wrench #10 O-ring (33589-VUF) VUB 3/4 Nylon Spacer FIGURE 8 Bracket MUR 1/4 Push Nut Bolt Retainer 1/4-20 x 1/2 Bolt (Located on Sub Case) Hold With This Wrench Lubricate O-ring (See Figure 10a, Page 14) 1/4-20 x 1/2 Bolt (Located on Sub Case) EDZ REV F 08/21/18, PG 18 OF 24 18

19 Wiring Diagram VUR JF8 TAN ORA BLK WHT RED WHT/RED WHT/YEL WHT/GRN AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW TEMP WIPER MODE WIPER FAN WIPER VIEWED FROM WIRE SIDE PRE-WIRED VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV E, 10/6/2017 TEMP MODE FAN *** WIDE OPEN THROTTLE SWITCH (OPTIONAL) PROGRAM * DASH LAMP (IF USED) ** CIRCUIT BREAKER 30 AMP HEATER CONTROL VALVE 19 * Dash Lamp Is Used Only With Type VUR Harness. ** Warning: Always Mount Circuit Breaker As Close to the Battery As Possible. (NOTE: Wire Between Battery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a Short Circuit). *** Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor EDZ REV F 08/21/18, PG 19 OF 24

20 WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY RED BLUE VIOLET WIRING HARNESS YELLOW ORANGE TAN GRAY RED GREEN NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH NOTE: YELLOW & ORANGE COMING FROM HARNESS ARE NOT USED. RED WHITE (IGNITION HOT TERMINAL) + 12V IGNITION SWITCH DASH BACK LIGHT+0-12v GRAY WIRE IS USED FOR PROGRAMING CONTROLS IF APPLICABLE RED GREEN RUN BAT Gen IV Wiring Connection Instruction Ignition Switch: Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched. Dash Light: Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light. FIREWALL WIRING HARNESS BINARY SAFETY SWITCH BLUE WHITE WHITE RED RED BLACK HEATER CONTROL VALVE BLUE RED CIRCUIT BREAKER 30 AMP WARNING: ALWAYS MOUNT CIRCUIT BREAKER AS CLOSE TO THE BATTERY AS POSSIBLE. (NOTE: WIRE BETWEEN BATTERY AND CIRCUIT BREAKER IS UNPROTECTED AND SHOULD BE CAREFULLY ROUTED TO AVOID A SHORT CIRCUIT). BLACK BLUE RED + COMPRESSOR BATTERY - LATCH WHITE CHASSIS GROUND NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURE CONNECTOR IS LATCHED FIRMLY. NOTE: CONNECT WHITE WIRES DIRECTLY TO (-) BATTERY TERMINAL EDZ REV F 08/21/18, PG 20 OF 24 Heater Control Valve: Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly. Binary/Trinary & Compressor: Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded. Trinary Switch: Connect According To Trinary Switch Wiring Diagram. Circuit Breaker/Battery: White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible. 20

21 Operation of Controls On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to control panel instructions for calibration procedure. Blower Speed This lever/knob controls blower speed, from OFF to HI. Mode Control This lever/knob controls the mode positions, from DASH to FLOOR to DEFROST, with a blend in between. Temperature Control This lever/knob controls the temperature, from HOT to COLD. Blower Speed Mode Control Temperature Control OFF DASH HOT FLR HI DEF COLD A C A/C Light Blower Speed Adjust to desired speed. Mode Control Adjust to desired mode position (DASH position recommended). A/C Operation Temperature Control For A/C operation, adjust to coldest position to engage compressor (Adjust between HOT and COLD to reach desired temperature). OFF DASH HOT FLR HI DEF COLD NOTE: A/C operation toggles on & off when thermostat lever is moved to the HOT or COLD ends of travel. A/C mode is indicated by the blue A/C light. A C Heat Operation Blower Speed Adjust to desired speed. Mode Control Adjust to desired mode position (FLOOR position recommended). Temperature Control For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature). OFF DASH HOT FLR HI DEF COLD A C Defrost/De-fog Operation Blower Speed Adjust to desired speed. Temperature Control Adjust to desired temperature. Mode Control Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level blend (Compressor is automatically engaged). OFF DASH HOT FLR HI DEF COLD A C EDZ REV F 08/21/18, PG 21 OF 24

22 Troubleshooting Guide Symptom Condition Checks Actions Notes Verify that all pins are inserted into plug. Ensure that no pins are bent or damaged in ECU. Check for damaged pins or wires in control head plug. 1a. Loss of ground on this wire renders control head inoperable. No other functions work. Verify continuity to chassis ground with white control head wire at various points. Check for damaged ground wire (white) in control head harness. Blower stays on high speed when ignition is on. See blower switch check procedure. Check for damaged blower switch or potentiometer and associated wiring. All other functions work. Be sure the small, 20 GA white ground wire is connected to the battery ground post. If it is, replace the ECU. Unplug 3-wire BSC control connector from ECU. If blower shuts off, ECU is either improperly wired or damaged. 1b. Check to ensure that no BSC wiring is damaged or shorted to vehicle ground. The BSC operates the blower by ground side pulse width modulation switching. The positive wire to the blower will always be hot. If the ground side of the blower is shorted to chassis ground, the blower will run on HI. Blower stays on high speed when ignition is on or off. No other part replacements should be necessary. Replace BSC (This will require removal of evaporator from vehicle). Unplug 3-wire BSC control connector from ECU. If blower stays running, BSC is either improperly wired or damaged. Danger: Never bypass safety switch with engine running. Serious injury can result. 2. Charge system or bypass pressure switch. System must be charged for compressor to engage. System is not charged. Compressor will not turn on (All other functions work) EDZ REV F 08/21/18, PG 22 OF 24 To check for proper pot function, check voltage at white/blue wire. Voltage should be between 0V and 5V, and will vary with pot lever position. Check continuity to ground on white control head wire. Check for 5V on red control head wire. Check for faulty A/C potentiometer or associated wiring (Not applicable to 3-pot controls). System is charged. Disconnected or faulty thermistor will cause compressor to be disabled. Check 2-pin connector at ECU housing. Check for disconnected or faulty thermistor. Red wire at A/C pot should have approximately 5V with ignition on. White wire will have continuity to chassis ground. White/ Blue wire should vary between 0V and 5V when lever is moved up or down. 3. Repair or replace pot/control wiring. Check for faulty A/C potentiometer or associated wiring. Compressor will not turn off (All other functions work). Replace relay. Check for faulty A/C relay. 22

23 Troubleshooting Guide (Cont.) 23 Symptom Condition Checks Actions Notes Ignition noise (radiated or conducted) will cause the system to shut down due to high voltage spikes. If this is suspected, check with a quality oscilloscope. Spikes greater than 16V will shut down the ECU. Install a radio capacitor at the positive post of the ignition coil (See radio capacitor installation bulletin). A faulty alternator or worn out battery can also result in this condition. Install capacitors on ignition coil and alternator. Ensure good ground at all points. Relocate coil and associated wiring away from ECU and ECU wiring. Check for burned or loose plug wires. 4. Noise interference from either ignition or alternator. Works when engine is not running; shuts off when engine is started (Typically early Gen IV, but possible on all versions). Check for positive power at heater valve green wire and blower red wire. Check for ground on control head white wire. Verify connections on power lead, ignition lead, and both white ground wires. System will not turn on, or runs intermittently. Will not turn on under any conditions. Verify proper meter function by checking the condition of a known good battery. Verify battery voltage is greater than 10 volts and less than 16. Check for damaged mode switch or potentiometer and associated wiring. 5. Typically caused by evaporator housing installed in a bind in the vehicle. Be sure all mounting locations line up and don t have to be forced into position. No mode change at all. Loss of mode door function. Check for obstructed or binding mode doors. Partial function of mode doors. Check for damaged stepper motor or wiring. System shuts off blower at 10V. Poor connections or weak battery can cause shutdown at up to 11V. Ensure all system grounds and power connections are clean and tight. Check for at least 12V at circuit breaker. Battery voltage is at least 12V. 6. Charge battery. Check for faulty battery or alternator. Battery voltage is less than 12V. Blower turns on and off rapidly EDZ REV F 08/21/18, PG 23 OF 24 Repair or replace. Check for damaged switch or pot and associated wiring. 7. Erratic functions of blower, mode, temp, etc. 8. Run red power wire directly to battery. This is an indicator that the system has been reset. Be sure the red power wire is on the battery post, and not on a switched source. Also, if the system is pulled below 7V for even a split second, the system will reset. When ignition is turned on, blower momentarily comes on, then shuts off. This occurs with the blower switch in the OFF position.

24 No. Qty. Part No. Description VUE PMN Packing List Evaporator Kit ( EDZ) Gen IV 4-Vent Evaporator Sub Case Accessory Kit Challenger/Cuda without A/C Checked By: Packed By: Date: 1 Gen IV 4-Vent Evap. Sub Case VUE 2 HOT COLD OFF HI DASH FLR DEF A C HOT COLD Accessory Kit PMN NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities EDZ REV F 08/21/18, PG 24 OF 24